Variable reflectance mirrors and windows

ABSTRACT

Various structures for variable reflectance rearview mirrors and variable transmittance windows are disclosed. One embodiment pertains to the provision of a polarized reflector in a rearview mirror. Another embodiment pertains to the provision of a switchable cholesteric liquid crystal element in a window. Yet another embodiment pertains to the provision of a plurality of apertures in a reflector layer of a rearview mirror where the apertures are sized and positioned in alignment with light emitting areas of a display positioned behind the reflector layer. In another embodiment, a moveable display or mirror element is attached to a rearview mirror housing.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.11/179,793 filed on Jul. 12, 2005, and, like that application, claimspriority to U.S. Provisional Application No. 60/587,113 filed on Jul.12, 2004, each of the foregoing applications being incorporated hereinby reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally pertains to a rearview mirror assemblyfor a vehicle and to windows (both architectural and vehicular). Moreparticularly, the present invention pertains to a rearview mirrorassembly incorporating an electronic device such as a display, lightsource, and/or light sensor, and to windows having a variabletransmittance.

It is desirable to provide electronic devices such as displays, sensors,signal lights, and indicator lights in a rearview mirror assembly of avehicle. There are several issues with designing a rearview mirrorassembly incorporating such an electronic device, particularly when therearview mirror assembly is an inside mirror assembly. If the electronicdevice is disposed adjacent the mirror element, it causes the insiderearview mirror assembly to have a larger area, which disadvantageouslyblocks more of the driver's view through the windshield. To address thisproblem, electronic devices are provided behind the mirror element so asto transmit or receive light through the mirror element. To allow forlight to be transmitted through the mirror element, a portion of thereflective layer of the mirror element is removed to define a window infront of the electronic device. This solution, however, reduces thereflective viewing area of the mirror assembly. Such a window alsoprovides further problems when the reflective layer serves as anelectrode for an electro-optic mirror element, such as an electrochromicmirror element. Thus, the window acts to eliminate the electrode acrossa portion of the electrochromic mirror element thereby causing anobjectionable non-uniform coloration of the mirror element when dimmed.

Commonly-assigned U.S. Pat. No. 6,700,692 discloses several solutionsfor incorporating electronic devices behind an electro-optic mirrorelement. In particular, this patent discloses the use of a“transflective” layer, which is partially reflective, partiallytransmissive. Although such a transflective layer is very effective formost forms of electronic devices, the transflective layer tends to blocka large percentage of light (passing about 10% of incident light). As aresult, the light from a display or light source behind the mirrorelement is not efficiently transmitted through the transflective layer.This becomes more problematic when a display is provided that displaysimages of variable brightness during periods of bright daylight. This isbecause the reflectivity of the transflective layer is still ratherhigh, and therefore, there is large light loss going throughtransflective layer producing poorer contrast. The above '692 patentfurther discloses an embodiment whereby slit-like, parallel aperturesare etched in the reflective layer in front of a compass display and/orin front of turn signal indicator lights. Such apertures are oftenrelatively large and few in number.

Recently, there has been a strong interest to provide a high resolutionvideo-type display in or around the position of an inside rearviewmirror assembly. One such application is backup control/vision on largevehicles such as sport utility vehicles (SUVs) or minivans where a clearview of what is behind is blocked by the car interior, seats, headrests,or other items. Positioning a camera on or near the back of the vehiclewith the image displayed on or near the rearview mirror can aid thedriver in backing up safely. This image could be displayed only when thevehicle is in reverse or it could be used to supplement or replace themirror when driving. In which case, it is desirable to have a mirroravailable as a back up for the camera/display system in case it fails.

Rearview mirrors have been proposed that include a video display thatpulls down from the mirror body for use in back up situations. Again,this is disadvantageous in that the video display blocks the driver'sview to the front of the vehicle. Further, the video display size islimited. Additionally, the driver must manually pull down the display,and the display is in a position that is vulnerable to damage bypassengers or objects.

Accordingly, there exists the need for a rearview mirror assemblyincorporating an electronic device where the electronic device maytransmit or receive light efficiently through the mirror element.

Variable transmission windows have been proposed for architecturalwindows and skylights and for sunroofs and windows for vehicles,including automobiles, trucks, recreational vehicles and trailers,airplanes, trains, and boats. One form of variable transmission windowthat has been proposed utilizes an electrochromic element that changesfrom a colorless state to a colored state in response to an appliedvoltage. Such electrochromic elements thus vary the transmittance of thewindow by changing color and absorbing light that is not to betransmitted. Such electrochromic windows are disclosed in U.S. Pat. Nos.6,239,898, 6,594,065, 6,407,847, 6,594,067, 6,671,080, 6,842,276,6,567,708, 6,597,489, 6,045,643, and 5,805,330. Electrochromic windowsfunction suitably for most applications. However, electrochromic windowsdo not respond instantaneously to an applied voltage and absorb and thusradiate heat.

Accordingly, there exists the need for a variable transmission windowthat more quickly responds to an applied voltage and that variestransmission by blocking both visible and infrared light withoutabsorbing light and thus generating heat inside the building.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a variable reflectance mirrorelement is provided for use in a rearview mirror assembly having anelectronic device positioned behind the mirror element fortransmitting/receiving light of having a first polarization. The mirrorelement comprises: a first substrate; a second substrate; a firstelectrode provided on a surface of the first substrate; a secondelectrode provided on a surface of the second substrate; anelectro-optic medium provided between the first and second substratesthat changes transmittance in response to a voltage applied across thefirst and second electrodes; and a polarized reflector provided on asurface of the second substrate for transmitting light of having thefirst polarization and reflecting light of having a second polarizationopposite the first polarization.

According to another embodiment of the present invention, a rearviewmirror assembly for a vehicle comprises: an electro-optic elementcomprising first and second electrodes, the electro-optic elementchanges reflectance in response to a voltage applied across the firstand second electrodes, wherein the second electrode comprises apolarized reflector for transmitting light of having a firstpolarization and reflecting light of having a second polarizationopposite the first polarization; and an electronic device positionedbehind the polarized reflector for transmitting/receiving light ofhaving the first polarization through the polarized reflector.

According to another aspect of the present invention, an electrochromicelement comprises: a first substrate; a second substrate spaced apartfrom the first substrate; a first electrode provided on a surface of thefirst substrate; a second electrode provided on a surface of the secondsubstrate; an electrochromic medium provided between the first andsecond substrates; and a polarized reflector provided on a surface ofone of the first and second substrates, the polarized reflectortransmits light of having a first polarization and reflects light ofhaving a second polarization opposite the first polarization.

According to another aspect of the present invention, a rearview mirrorassembly is provided for a vehicle comprising: a housing adapted forattachment to the vehicle; a display positioned within the housing; anda mirror element moveably mounted to the housing, the mirror elementmovable between a first position in front of the display, and a secondposition away from the display.

According to another aspect of the present invention, a rearview mirrorassembly is provided for a vehicle comprising: a housing adapted forattachment to the vehicle; a mirror element positioned within thehousing; and a display moveably mounted to the housing, the displaymovable between a first position where the display may be viewed by avehicle occupant, and a second position where the display may not bereadily viewed by a vehicle occupant.

According to another aspect of the present invention, an electro-opticvariable transmittance window comprises a switchable cholesteric elementhaving a pitch that varies in response to an applied voltage so as tovary the transmittance of the electro-optic variable transmittancewindow.

According to another aspect of the present invention, a rearview mirrorassembly is provided for a vehicle comprising: a substrate; a reflectivelayer applied to a surface of the substrate; and a display having aplurality of light emitting areas, wherein the reflective layer has aplurality of apertures formed therethrough, each aperture beingassociated and substantially aligned with the light emitting regions ofthe display.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front elevational view schematically illustrating a rearviewmirror system constructed in accordance with the present invention;

FIG. 2 is a front elevational view schematically illustrating an insiderearview mirror assembly constructed in accordance with one embodimentof the present invention;

FIG. 3A is a cross-sectional view of the rearview mirror element shownin FIG. 2 as taken along line III-III according to one embodiment of thepresent invention;

FIG. 3B is a cross-sectional view of the rearview mirror element shownin FIG. 2 as taken along line III-III according to another embodiment ofthe present invention;

FIG. 3C is a cross-sectional view of the rearview mirror element shownin FIG. 2 as taken along line III-III according to another embodiment ofthe present invention;

FIG. 3D is a cross-sectional view of the rearview mirror element shownin FIG. 2 as taken along line III-III according to another embodiment ofthe present invention;

FIG. 3E is a cross-sectional view of the rearview mirror element shownin FIG. 2 as taken along line III-III according to another embodiment ofthe present invention;

FIG. 4 is a close up cross-sectional of area IV shown in FIG. 3A;

FIG. 5 is a front elevational view schematically illustrating an insiderearview mirror assembly constructed in accordance with a secondembodiment of the present invention;

FIG. 6 is a front elevational view schematically illustrating an insiderearview mirror assembly constructed in accordance with anotherembodiment of the present invention;

FIG. 7A is a close up view of area VII shown in FIG. 6;

FIG. 7B is a close up view of area VII shown in FIG. 6 of an alternativeconstruction from that shown in FIG. 7A;

FIG. 8A is a cross-sectional view of the rearview mirror element shownin FIG. 6 as taken along line VIII-VIII according to one embodiment ofthe present invention;

FIG. 9A is a close up view of area IX shown in FIG. 8;

FIG. 9B is a close up view of area IX shown in FIG. 8 of an alternativeconstruction from that shown in FIG. 9A with the display in a visibleposition;

FIG. 9C is a close up view of area IX shown in FIG. 8 of the sameconstruction as shown in FIG. 9B but with the display in a nonvisibleposition;

FIG. 9D is a close up view of area IX shown in FIG. 8 of an alternativeconstruction from that shown in FIG. 9A;

FIG. 8B is a cross-sectional view of the rearview mirror element shownin FIG. 6 as taken along line VIII-VIII according to another embodimentof the present invention;

FIG. 8C is a cross-sectional view of the rearview mirror element shownin FIG. 6 as taken along line VIII-VIII according to another embodimentof the present invention;

FIG. 10 is an electrical circuit diagram in block form of a rear visionsystem constructed in accordance with the present invention;

FIGS. 11A and 11B are side elevational views schematically illustratingan inside rearview mirror assembly constructed in accordance withanother embodiment of the present invention;

FIGS. 12A and 12B are side elevational views schematically illustratingan inside rearview mirror assembly constructed in accordance withanother embodiment of the present invention;

FIG. 13A is an elevational view of the side of a rearview mirrorassembly constructed according to the present invention;

FIG. 13B is an elevational view of the rear of a rearview mirrorassembly constructed according to the present invention;

FIG. 13C is a plan view of the top of a rearview mirror assemblyconstructed according to the present invention;

FIG. 14A is an elevational view of the front of a rearview mirrorassembly constructed according to the present invention;

FIG. 14B is a plan view of the top of a rearview mirror assemblyconstructed according to the present invention;

FIG. 15 is a cross-sectional view of a window constructed in accordancewith the present invention;

FIG. 16 is a cross-sectional view of an insulated window constructed inaccordance with one embodiment of the present invention;

FIG. 17 is a cross-sectional view of an insulated window constructed inaccordance with another embodiment of the present invention;

FIG. 18 is a cross-sectional view of an insulated window constructed inaccordance with another embodiment of the present invention; and

FIG. 19 is a cross-sectional view of a vehicle window constructed inaccordance with the present invention.

DESCRIPTION OF THE INVENTION

The present invention pertains to various structures for variablereflectance rearview mirrors and variable transmittance windows. Oneembodiment pertains to the provision of a polarized reflector in arearview mirror. Another embodiment pertains to the provision of aswitchable cholesteric liquid crystal element in a window. Yet anotherembodiment pertains to the provision of a plurality of apertures in areflector layer of a rearview mirror where the apertures are sized andpositioned in alignment with light emitting areas of a displaypositioned behind the reflector layer. In another embodiment, a moveabledisplay or mirror element is attached to a rearview mirror housing.

According to one of the above embodiments, the present invention maygenerally include a rearview mirror assembly comprising a variablereflectance mirror element and an electronic device positioned behindthe mirror element so as to transmit or receive light through the mirrorelement. Unlike prior rearview variable reflectance mirror elements,however, the mirror element used in the present invention, may utilize apolarized reflector that transmits light having a first polarization,while reflecting light having a second polarization opposite the firstpolarization. The electronic device emits light or receives light havingthe first polarization such that the light passes very efficientlythrough the mirror element with almost no loss. Approximately half ofthe ambient light, on the other hand, is reflected so that the mirrorelement acts as an effective rearview mirror. The polarized reflectormay function as one of the electrodes of the variable reflectance mirrorelement.

The reflective polarizer may be a “wire grid” type of polarizer thatreflects (specularly) one plane of light polarization and transmits theother. A display or other light source that emits polarized light wouldnot suffer a large drop in brightness if it is oriented such that itspolarized light is transmitted through the mirror element and notreflected. If a light source or light emitting display that does notemit polarized light is used behind a “wire polarizer” mirror element, aportion of the light is transmitted and a portion of the light isreflected. Both the transmitted and reflected light is polarized. Thepolarized reflected light could be de-polarized by reflective scatteringand part of that light will then be transmitted by the mirror element orthe plane of polarization of the light could be rotated 90 degrees andreflected back through the “wire grid” polarizer. This will enhance thedisplay brightness. Similar techniques could be used to utilize ambientlight that is transmitted through the wire grid polarizer into thedisplay/reflector assembly.

Suitable “wire grid” polarizers that can be used for this applicationare available from Moxtek of Orem, Utah, and NanoOpto Corporation ofSomerset, N.J. The use of “wire grid” polarizers in mirror/displaydevices is disclosed in WO 2005/050267 A1, WO 2005/024500 A1, and WO03/079318 A1, the entire disclosures of which are incorporated herein byreference.

If a TFT LCD is used as a video display, and the display is orientedsuch that its polarized light is transmitted by the wire grid polarizer,almost 100 percent of the light it emits is transmitted and almost 50percent of ambient light is specularly reflected by the mirror. Theresult is a high brightness “display on demand” mirror where almost nodisplay brightness is lost yet the “mirror” is near 50 percentreflective to ambient light.

This “wire grid” polarizer/mirror and display assembly could be used “asis” in a non-dimming rearview mirror assembly or it could be laminatedto or attached to an electro-optic dimming window (LCD or electrochromicelement) to make a dimming “wire grid” polarizer/mirror and displayassembly with variable reflectance. One advantage of using such anelectro-optic element in front of the reflective polarizer is that theelectro-optic element may be made less transmissive when the display isturned on. The ambient light striking the mirror element passes throughthe electro-optic element twice while the light from the display orlight source only passes through once. Thus, by dimming theelectro-optic element when the display is on, twice as much of theambient light is absorbed as the light from the display or light sourcethereby increasing the relative contrast ratio of the display duringhigh brightness ambient conditions.

A typical “wire grid” polarizer available from Moxtek (ProFlux™ type) ismade by coating glass with a reflective aluminum layer. This aluminumlayer is then patterned into straight lines and spaces using typicalsemiconductor patterning technology. The beginning of line to beginningof line spacing is about 0.15 microns (150 nm). The aluminum line widthand spacing width can vary, but looks to be about a 60 AC/40 size ratioby SEM analysis. The ratio of the metallic line width to space width canbe varied to change the ratio of reflection to transmission. Such anassembly could be used as an electrode in an electro-optic element suchas an electrochromic device or an LCD device. For example, if a silveror silver alloy film is patterned in such a way, it could be used as athird surface reflector electrode in an electrochromic mirror element.The metal grid layer could be overcoated or undercoated with atransparent conductor, such as ITO, ZnO, or tin oxide to enhanceconductivity or electrode stability. The wire grid layer could also beovercoated or undercoated with a thin layer of reflective material suchas silver, silver/gold, gold, aluminum, or other reflective metal ormetal alloy to enhance reflectivity. The reflectivity could also beenhanced by an overcoat or undercoat of a dichroic film stack orenhanced by such typical means of increasing the reflectivity of silveror aluminum films. In this way, a dimming mirror assembly can be madethat will support a high brightness, high resolution display assembly.

Other methods used to reflect light of one type of polarization(circular or linear) and transmit light of the second type ofpolarization are known that may be used as the polarized reflector of avariable reflectivity mirror. A laminated foil made of multiple layersof plastic film wherein some or all of the films layers have an internalmolecular orientation (induced by stretching or other means) thatinduces a directional difference in refractive index can be constructedsuch that the laminated foil reflects one type of polarization andtransmits the second type of polarization.

Cholesteric polarizers can also be made that will reflect one type ofpolarization and transmit the second type of polarization, and thusserve as the polarized reflector for a variable reflectivity mirror.These polarizers can be made such that they are voltage switchable. Inother words, these polarizers can be switched from reflecting the firsttype of polarization and transmitting the second type of polarization totransmitting both types of polarization or they can be switched fromreflecting the second type of polarization and transmitting the firsttype of polarization to transmitting both types of polarization. Thewavelength of light that is reflected by these cholesteric polarizers isdependant on the pitch of the twist in the cholesteric structure. Asingle pitch cholesteric structure reflects a fairly narrow (<100 nm)bandwidth of light. A variable pitch cholesteric structure reflects awider bandwidth of light. The greater the variation in cholestericpitch, the wider the bandwidth of light that is reflected. Such avariable pitch cholesteric structure is described in U.S. Pat. Nos.5,762,823 and 5,798,057, the entire disclosures of which areincorporated herein by reference.

One or two of these switchable variable pitch cholesteric polarizers canbe used in combination with a light emitting display device to constructa variable reflectance rearview mirror with enhanced displayviewability. One switchable variable pitch cholesteric polarizer incombination with a typical TFT LCD assembly can be configured to eitherreflect one type of polarization and transmit the second type ofpolarization that the TFT LCD emits or transmit both types ofpolarization. This construct enables four modes of operation: 1) mirrorat ˜50% reflection, display off; 2) mirror at ˜50% reflection, displayon; 3) mirror at ˜0% reflection, display on; and 4) mirror at ˜0%reflection, display off (note: the reflectance of the mirror assembly inthis configuration would approximately be the magnitude of reflectionoff of the first substrates surface or about 4%).

Two switchable variable pitch cholesteric polarizers used in combinationwith a typical TFT LCD add one additional high reflectance mirror modeto the above. In the high reflectance mode, the first switchablereflective polarizer would reflect one type of polarization and transmitthe second and the second switchable reflective polarizer would reflectthe second type of polarization. In the mid reflectance mode, onereflective polarizer would reflect one type of polarization and transmitthe second type of polarization which is the same polarization of lightthe TFT LCD emits. In the low reflectance mode, both switchablereflective polarizers would transmit both types of polarization. Thisconstruction enables five modes of operation: 1) mirror at ˜100%reflection; 2) mirror at ˜50% reflection, display off; 3) mirror at ˜50%reflection, display on; 4) mirror at first surface reflection (˜4%),display off; and 5) mirror at first surface reflection (˜4%), displayon. Additional reflectance states may be obtained when using one or moreswitchable variable pitch cholesteric reflective polarizers incombination with an electrochromic element positioned between the viewerand the polarizer(s). If additional levels of reflectivity are desired,an electrochromic element may be disposed in front of the cholestericelement(s), or the cholesteric element(s) may be used alone to a two- orthree-state variable reflectivity mirror.

As described further below, switchable variable pitch cholestericreflective polarizers can also be used in vehicle windows, sunroofs,architectural windows, and skylights.

Another embodiment of the present invention is based on the recognitionby the inventors that displays (particularly TFT LCD displays) emitlight from well-defined relatively small light emitting areasconstituting only about 30 percent of the total surface area of thedisplay. According to this embodiment, very small holes or slits arecreated in a highly reflective coating and are aligned with the patternof light emitting areas from the display. Each pixel has a holepositioned to allow light to pass with little attenuation toward thedriver of defined user location. By creating holes of the correct sizealigned with the emitting areas of the display, an average reflectionpercentage of 60% or higher can be achieved and still have very littleattenuation at the points of transmission. Unlike the embodimentsdisclosed in the above-referenced U.S. Pat. No. 6,700,692, the holes orslits are much smaller and are used much more efficiently so as toreflect more light over a greater area in front of the display while notblocking much of any light from the display so as to provide a greatertransmission percentage from the display. With this construction, thehole pattern may be provided over the entire mirror area and a largedisplay may be provided behind a significant area of the mirror.

This concept can be enhanced in several ways. First the holes need notbe round with uniform edges. Holes with complex edges can be made lessvisible. The hole regions can be made transflective to further disguisethe hole. This sacrifices some transmission efficiency for betterreflector appearance.

It is desirable to disguise the display region such that the display ismore of an “on demand” display. This can be further enhanced byemploying the hole pattern over the entire mirror area. It can befurther enhanced by matching the reflection of the basic display regionsin the regions not backed up by the display.

Further, there is another form allowing a very high reflectionpercentage and no attenuation of the display. This can be achieved byusing a shutter action. The display top surface may carry a highreflection surface matching that of the mirror. When aligned (shutteropen), holes in the display reflecting surface align with holes in themirror reflecting surface and the display becomes visible. If thedisplay is displaced, the holes in the mirror align with the reflectingsurface of the display. This yields a 100% reflecting area. Since thereflecting surfaces can be in direct contact, the only opticaldistortion is due to the thickness of the mirror reflecting layercausing very small ridges around the holes. The resulting opticaldistortions are virtually invisible for viewing angles of use inrearview mirrors.

The shutter movement can be made using ceramic piezo-electrictransducers. Movement can include a component to separate the surfacesas part of allowing the display to shine through. This would avoid anysurface damage due to shutter movement.

The concept of aligning apertures through the reflector with the areasof display emission meets the challenge of creating a highly reflectingsurface and having a high degree of display transmission because itseparates the surface requirements. It has the effect of impacting onlythe display aperture regions. Thus the vast majority of the surfacefunctions as well as a conventional reflector. As a result, means can beused in the aperture areas to switch between reflector and transmissionthat would not be suitable if applied over the entire area. Thisapproach is inherently very robust as a failure only impacts the displayholes not the primary reflecting surface.

There is a possible synergism between the above concept and ways ofcreating and removing reflecting surfaces using electro-chemical means,such as the reversible electro-deposition means disclosed in U.S. Pat.Nos. 5,903,382, 5,056,899, 6,111,685, 6,166,847, 6,188,505, 6,310,714,and 6,433,914, and in U.S. Patent Application Publication Nos. US2005/0078347 A1 and US 2005/0111070 A1, the entire disclosures of whichare incorporated herein by reference. In mirrors constructed usingreversible electro-deposition, the reflective layer of the mirror isselectively and dynamically plated with reflective particles. The mirrorexhibits a reflective state only when a voltage is applied. Thus, in theevent of a failure, the mirrors are typically not reflective. Further,there are often challenges to obtaining a good specular reflector usingreversible electro-deposition. Many of these problems can be addressedby using a permanent reflective layer having a plurality of apertures asdiscussed above and using the electro-deposition particles to onlyprovide reflectivity in the apertures when the display is not in use. Byusing a non-conductive mask over all but the apertures corresponding tothe light emitting areas of the display, the reflecting area produced bythe electro-deposition particles can be grossly reduced and the impactof imperfections in the reforming process can be better tolerated.Lesser reflecting area and imperfection tolerance should result in muchfaster cycle times using lower currents. The display can be effected butthe mirror area is always present so a fail to clear is assured.

A variation on “digital paper” is also a potential means to fill theapertures in the reflective layer thus raising reflection image quality.An example of “digital paper” is disclosed in U.S. Pat. No. 6,800,871,the entire disclosure of which is incorporated herein by reference. Inthis case, instead of rotating bi-colored particles as is done in“digital paper” applications, metallic particles are moved into and outof the aperture areas. This could be done by driving the metallicparticles forward to the aperture areas and rearward to non-apertureareas. Indium tin oxide (ITO) or other transparent conductive coatingsmay be used over the apertures to create the field drawing theseparticles. Voltage on the surrounding surface and these particles moveto the reflecting areas opening the apertures and when the apertureareas are charged the particles will fill the apertures.

The key in each case is that the apertures represent very small defectareas so less than perfect aperture surfaces will not create poorviewing conditions. Thus, means to fill the holes can be used thatresult in less than perfect surfaces in these holes.

By placing an optical device between the display and the mirror surface,light from the display can be converged so more light can be passedthrough a smaller aperture. The light converges to a very small diameterthen diverges at the same angle. If the point of convergence to asmaller diameter is approximately aligned with the holes in thereflecting coating a much larger field of view may be achieved usingsmaller aperture holes and a greater spacing between the display and themirror surface. This would be more practical when the reflector isprovided on the third surface of the mirror element.

An appropriate optical device would be a plastic sheet with molded lensdetails for every pixel. Light from the display radiates to the lenswhere it is converged, through the reflecting layer hole and thendiverges at the same angle as the convergence. To the viewer the displayregions seem larger and the display can be seen from angles greater thancould be achieved if the optical device were removed.

This sheet like optical element can be made by the same processes asthose currently used to make lenticular lens sheets forauto-stereoscopic displays only in this case the lenses would bespherical. It should be noted an auto-stereoscopic display through areflecting surface can also be made using this same basic idea only thehole patterns in the reflecting layer would be formed as narrow verticalslits.

Having generally described various aspects of the present invention,which may be used separately or in various combinations, more detaileddescriptions are provided below of the various embodiments thereof.

FIG. 1 shows a rearview mirror system 100 constructed in accordance withthe present invention. Mirror system 100 includes an inside rearviewmirror assembly 110 and may include one or more outside rearview mirrorassemblies 111 a and 111 b for the driver-side and passenger-side,respectively, all of which are adapted to be installed on a motorvehicle in a conventional manner and where the mirrors face the rear ofthe vehicle and can be viewed by the driver of the vehicle to provide arearward view. Inside mirror assembly 110 and outside rearview mirrorassemblies 111 a and 111 b may be electro-optic and thus may incorporatelight-sensing electronic circuitry of the type illustrated and describedin U.S. Pat. No. 5,204,778 or U.S. Pat. No. 5,451,822, and othercircuits capable of sensing glare and ambient light and supplying adrive voltage to the electro-optic element. Mirror assemblies 110, 111a, and 111 b are essentially identical in that like numbers identifycomponents of the inside and outside mirrors. These components may beslightly different in configuration, but function in substantially thesame manner and obtain substantially the same results as similarlynumbered components. For example, the shape of the front glass elementof inside mirror 110 is generally longer and narrower than outsidemirrors 111 a and 111 b. There are also some different performancestandards placed on inside mirror 110 compared with outside mirrors 111a and 111 b. Also, in the United States (as supplied by the automobilemanufacturers), the passenger-side mirror 111 b typically has aspherically bent or convex shape, whereas the driver-side mirror 111 aand inside mirror 110 presently must be flat. In Europe, the driver-sidemirror 111 a is commonly flat or aspheric, whereas the passenger-sidemirror 111 b has a convex shape. In Japan, both outside mirrors have aconvex shape. The following description is generally applicable to allmirror assemblies of the present invention.

FIG. 2 shows an inside rearview mirror assembly 110 a constructed inaccordance with one embodiment of the present invention. According tothis embodiment, the mirror assembly may include a mirror element 115having a polarized reflector 174 and a video display 170 for displayinga scene to the rear of the vehicle as captured by a camera 426 (FIG.11). Video display 170 preferably is configured to emit light that ispolarized in the same orientation as the polarized reflector 174, whichis also preferably in the same orientation as transmitted throughconventional polarizing sun glasses as may be worn by the driver.

Video display 170 may extend the entire area of the mirror assembly 110a or may only be provided across a portion of the mirror assembly. Videodisplay 170 may be part of a rear vision system including one or morevideo cameras 426 that supply a video signal to display 170 for displaythereon. The video camera(s) 426 may be mounted so as to capture imagesto the rear of the vehicle to assist the driver while backing up or toserve as a full time replacement or supplement to a rearview mirror.Examples of rear vision systems with which the present invention may beused are disclosed in commonly assigned U.S. Pat. No. 6,672,745 and inpublished U.S. Patent Application Publication No. 2003/0103141 A1, theentire disclosures of which are incorporated herein by reference.

As described below with respect to FIGS. 3A-3E, the structure of themirror/display element used in rearview assembly 110 a may vary.

FIG. 3A shows a cross-sectional view of a first example of anelectrochromic mirror element 115 a that may be used in mirror assembly110 a. Electrochromic mirror element 115 a has a front transparentelement 112 having a front surface 112 a and a rear surface 112 b, and arear element 114 having a front surface 114 a and a rear surface 114 b.For clarity of description of such a structure, the followingdesignations will be used hereinafter. The front surface 112 a of thefront glass element will be referred to as the first surface, and theback surface 112 b of the front glass element as the second surface. Thefront surface 114 a of the rear glass element will be referred to as thethird surface, and the back surface 114 b of the rear glass element asthe fourth surface. A chamber 125 is defined by a layer of transparentconductor 128 (carried on second surface 112 b), an electrode 120(disposed on third surface 114 a), and an inner circumferential wall 132of sealing member 116. An electrochromic medium 126 is contained withinchamber 125.

As broadly used and described herein, the reference to an electrode orlayer as being “carried” on a surface of an element, refers to bothelectrodes or layers that are disposed directly on the surface of anelement or disposed on another coating, layer or layers that aredisposed directly on the surface of the element.

Front transparent element 112 may be any material which is transparentand has sufficient strength to be able to operate in the conditions,e.g., varying temperatures and pressures, commonly found in theautomotive environment. Front element 112 may comprise any type ofborosilicate glass, soda lime glass, float glass, or any other material,such as, for example, a polymer or plastic, that is transparent in thevisible region of the electromagnetic spectrum. Front element 112 ispreferably a sheet of glass. The rear element 114 should meet theoperational conditions outlined above, except that it does not need tobe transparent in all applications, and therefore may comprise polymers,metals, glass, ceramics, and preferably is a sheet of glass.

The coatings of the third surface 114 a are sealably bonded to thecoatings on the second surface 112 b in a spaced-apart and parallelrelationship by a seal member 116 disposed near the outer perimeter ofboth second surface 112 b and third surface 114 a. Seal member 116 maybe any material that is capable of adhesively bonding the coatings onthe second surface 112 b to the coatings on the third surface 114 a toseal the perimeter such that electrochromic material 126 does not leakfrom chamber 125. Optionally, the layer of transparent conductivecoating 128 and the layer of reflector/electrode 120 may be removed overa portion where the seal member is disposed (not the entire portion,otherwise the drive potential could not be applied to the two coatings).In such a case, seal member 116 should bond well to glass.

The performance requirements for a perimeter seal member 116 used in anelectrochromic device are similar to those for a perimeter seal used ina liquid crystal device (LCD), which are well known in the art. The sealpreferably has good adhesion to glass, metals and metal oxides; has lowpermeabilities for oxygen, moisture vapor, and other detrimental vaporsand gases; and does not interact with or poison the electrochromic orliquid crystal material it is meant to contain and protect. Theperimeter seal can be applied by means commonly used in the LCDindustry, such as by silk-screening or dispensing. Totally hermeticseals, such as those made with glass frit or solder glass, can be used,but the high temperatures involved in processing (usually near 450° C.)this type of seal can cause numerous problems, such as glass substratewarpage, changes in the properties of transparent conductive electrode,and oxidation or degradation of the reflector. Because of their lowerprocessing temperatures, thermoplastic, thermosetting or UV curingorganic sealing resins are preferred. Such organic resin sealing systemsfor LCDs are described in U.S. Pat. Nos. 4,297,401, 4,418,102,4,695,490, 5,596,023, and 5,596,024. Because of their excellent adhesionto glass, low oxygen permeability and good solvent resistance,epoxy-based organic sealing resins are preferred. These epoxy resinseals may be UV curing, such as described in U.S. Pat. No. 4,297,401, orthermally curing, such as with mixtures of liquid epoxy resin withliquid polyamide resin or dicyandiamide, or they can be homopolymerized.The epoxy resin may contain fillers or thickeners to reduce flow andshrinkage such as fumed silica, silica, mica, clay, calcium carbonate,alumina, etc., and/or pigments to add color. Fillers pretreated withhydrophobic or silane surface treatments are preferred. Cured resincrosslink density can be controlled by use of mixtures ofmono-functional, di-functional, and multi-functional epoxy resins andcuring agents. Additives such as silanes or titanates can be used toimprove the seal's hydrolytic stability, and spacers such as glass beadsor rods can be used to control final seal thickness and substratespacing. Suitable epoxy resins for use in a perimeter seal member 116include, but are not limited to: “EPON RESIN” 813, 825, 826, 828, 830,834, 862, 1001F, 1002F, 2012, DPS-155, 164, 1031, 1074, 58005, 58006,58034, 58901, 871, 872, and DPL-862 available from Shell Chemical Co.,Houston, Tex.; “ARALITE” GY 6010, GY 6020, CY 9579, GT 7071, XU 248, EPN1139, EPN 1138, PY 307, ECN 1235, ECN 1273, ECN 1280, MT 0163, MY 720,MY 0500, MY 0510, and PT 810 available from Ciba Geigy, Hawthorne, N.Y.;and “D.E.R.” 331, 317, 361, 383, 661, 662, 667, 732, 736, “D.E.N.” 431,438, 439 and 444 available from Dow Chemical Co., Midland, Mich.Suitable epoxy curing agents include V-15, V-25, and V-40 polyamidesfrom Shell Chemical Co.; “AJICURE” PN-23, PN-34, and VDH available fromAjinomoto Co., Tokyo, Japan; “CUREZOL” AMZ, 2MZ, 2E4MZ, C11Z, C17Z, 2PZ,2IZ, and 2P4MZ available from Shikoku Fine Chemicals, Tokyo, Japan;“ERISYS” DDA or DDA accelerated with U-405, 24EMI, U-410, and U-415available from CVC Specialty Chemicals, Maple Shade, N.J.; and “AMICURE”PACM, 352, CG, CG-325, and CG-1200 available from Air Products,Allentown, Pa. Suitable fillers include fumed silica such as “CAB-O-SIL”L-90, LM-130, LM-5, PTG, M-5, MS-7, MS-55, TS-720, HS-5, and EH-5available from Cabot Corporation, Tuscola, Ill.; “AEROSIL” R972, R974,R805, R812, R812S, R202, US204, and US206 available from Degussa, Akron,Ohio. Suitable clay fillers include BUCA, CATALPO, ASP NC, SATINTONE 5,SATINTONE SP-33, TRANSLINK 37, TRANSLINK 77, TRANSLINK 445, andTRANSLINK 555 available from Engelhard Corporation, Edison, N.J.Suitable silica fillers are SILCRON G-130, G-300, G-100-T, and G-100available from SCM Chemicals, Baltimore, Md. Suitable silane couplingagents to improve the seal's hydrolytic stability are Z-6020, Z-6030,Z-6032, Z-6040, Z-6075, and Z-6076 available from Dow CorningCorporation, Midland, Mich. Suitable precision glass microbead spacersare available in an assortment of sizes from Duke Scientific, Palo Alto,Calif.

The layer of a transparent electrically conductive material 128 isdeposited on the second surface 112 b to act as an electrode.Transparent conductive material 128 may be any material which bonds wellto front element 112, is resistant to corrosion to any materials withinthe electrochromic device, resistant to corrosion by the atmosphere, hasminimal diffuse or specular reflectance, high light transmission, nearneutral coloration, and good electrical conductance. Transparentconductive material 128 may be fluorine-doped tin oxide, doped zincoxide, indium zinc oxide (Zn₃In₂O₆), indium tin oxide (ITO),ITO/metal/ITO (IMI) as disclosed in “Transparent ConductiveMultilayer-Systems for FPD Applications,” by J. Stollenwerk, B. Ocker,K. H. Kretschmer of LEYBOLD AG, Alzenau, Germany, the materialsdescribed in above-referenced U.S. Pat. No. 5,202,787, such as TEC 20 orTEC 15, available from Libbey Owens-Ford Co. of Toledo, Ohio, or othertransparent conductors. Generally, the conductance of transparentconductive material 128 will depend on its thickness and composition.IMI generally has superior conductivity compared with the othermaterials. IMI is, however, known to undergo more rapid environmentaldegradation and suffer from interlayer delamination. The thickness ofthe various layers in the IMI structure may vary, but generally thethickness of the first ITO layer ranges from about 10 Å to about 200 Å,the metal ranges from about 10 Å to about 200 Å, and the second layer ofITO ranges from about 10 Å to about 200 Å. If desired, an optional layeror layers of a color suppression material 130 may be deposited betweentransparent conductive material 128 and the second surface 112 b tosuppress the reflection of any unwanted portions of the electromagneticspectrum.

In accordance with the embodiment shown in FIG. 3A, a combinationreflector/electrode 120 is disposed on third surface 114 a.Reflector/electrode 120 may include a “wire grid” polarizing structure174 discussed above and may optionally include an additional layer 176.As mentioned above, this additional layer 176 may be a layer of atransparent conductive material or may be a reflective conductivematerial.

FIG. 4 shows a magnified view of area IV shown in FIG. 3A. As shown, thewire grid reflective polarizer 174 includes a plurality of closelyspaced, narrow parallel strips 175 of silver, silver alloy, or otherreflective material.

It is desirable in the construction of outside rearview mirrors toincorporate thinner glass in order to decrease the overall weight of themirror so that the mechanisms used to manipulate the orientation of themirror are not overloaded. Decreasing the weight of the device alsoimproves the dynamic stability of the mirror assembly when exposed tovibrations. Alternatively, decreasing the weight of the mirror elementmay permit more electronic circuitry to be provided in the mirrorhousing without increasing the weight of the mirror housing. Heretofore,no electrochromic mirrors incorporating a solution-phase electrochromicmedium and two thin glass elements have been commercially available,because thin glass suffers from being flexible and prone to warpage orbreakage, especially when exposed to extreme environments. This problemis substantially improved by using an improved electrochromic deviceincorporating two thin glass elements having an improved gel material.This improved device is disclosed in commonly assigned U.S. Pat. No.5,940,201 entitled “ELECTROCHROMIC MIRROR WITH TWO THIN GLASS ELEMENTSAND A GELLED ELECTROCHROMIC MEDIUM,” filed on Apr. 2, 1997. The entiredisclosure of this patent is incorporated herein by reference. Theaddition of the combined reflector/electrode onto the third surface ofthe device further helps remove any residual double imaging resultingfrom the two glass elements being out of parallel. Thus, in accordancewith the present invention, chamber 125 contains a free-standing gelthat cooperatively interacts with thin glass elements 112 and 114 toproduce a mirror that acts as one thick unitary member rather than twothin glass elements held together only by a seal member. Infree-standing gels, which contain a solution and a cross-linked polymermatrix, the solution is interspersed in a polymer matrix and continuesto function as a solution. Also, at least one solution-phaseelectrochromic material is in solution in the solvent and therefore aspart of the solution is interspersed in the polymer matrix (thisgenerally being referred to as “gelled electrochromic medium” 126). Thisallows one to construct a rearview mirror with thinner glass in order todecrease the overall weight of the mirror while maintaining sufficientstructural integrity so that the mirror will survive the extremeconditions common to the automobile environment. This also helpsmaintain uniform spacing between the thin glass elements which improvesuniformity in the appearance (e.g., coloration) of the mirror. Thisstructural integrity results because the free-standing gel, the firstglass element 112, and the second glass element 114, which individuallyhave insufficient strength characteristics to work effectively in anelectrochromic mirror, couple in such a manner that they no longer moveindependently but act as one thick unitary member. This stabilityincludes, but is not limited to, resistance to, flexing, warping, bowingand breaking, as well as improved image quality of the reflected image,e.g., less distortion, double image, color uniformity, and independentvibration of each glass element. However, while it is important tocouple the front and rear glass elements, it is equally important (ifnot more so) to ensure that the electrochromic mirror functionsproperly. The free-standing gel should bond to the electrode layers(including the reflector/electrode if the mirror has a third surfacereflector) on the walls of such a device, but not interfere with theelectron transfer between the electrode layers and the electrochromicmaterial(s) disposed in the chamber 125. Further, the gel should notshrink, craze, or weep over time such that the gel itself causes poorimage quality. Ensuring that the free-standing gel bonds well enough tothe electrode layers to couple the front and rear glass elements anddoes not deteriorate over time, while allowing the electrochromicreactions to take place as though they were in solution, is an importantaspect of the present invention.

To perform adequately, a mirror should accurately represent thereflected image, and this cannot be accomplished when the glass elements(to which the reflector is attached) tend to bend or bow while thedriver is viewing the reflected image. The bending or bowing occursmainly due to pressure points exerted by the mirror mounting andadjusting mechanisms and by differences in the coefficients of thermalexpansion of the various components that are used to house the exteriormirror element. These components include a carrier plate used to attachthe mirror element to the mechanism used to manipulate or adjust theposition of the mirror (bonded to the mirror by an adhesive), a bezel,and a housing. Many mirrors also typically have a potting material as asecondary seal. Each of these components, materials, and adhesives havevarying coefficients of thermal expansion that will expand and shrink tovarying degrees during heating and cooling and will exert stress on theglass elements 112 and 114. On very large mirrors, hydrostatic pressurebecomes a concern and may lead to double imaging problems when the frontand rear glass elements bow out at the bottom and bow in at the top ofthe mirror. By coupling the front and rear glass elements the thinglass/free-standing gel/thin glass combination act as one thick unitarymember (while still allowing proper operation of the electrochromicmirror) and thereby reduce or eliminate the bending, bowing, flexing,double image, and distortion problems and non-uniform coloring of theelectrochromic medium.

The cooperative interaction between the free-standing gel and the thinglass elements of the present invention also improves the safety aspectsof the electrochromic mirror 110 having thin glass elements. In additionto being more flexible, thin glass is more prone to breakage than thickglass. By coupling the free-standing gel with the thin glass, theoverall strength is improved (as discussed above) and further restrictsshattering and scattering and eases clean-up in the case of breakage ofthe device.

The improved cross-linked polymer matrix used in the present inventionis disclosed in commonly assigned U.S. Pat. No. 5,928,572 entitled“ELECTROCHROMIC LAYER AND DEVICES COMPRISING SAME” filed on Mar. 15,1996, and the International patent application filed on or about Mar.15, 1997, and claiming priority to this U.S. patent. The entiredisclosures of these two applications, including the referencescontained therein, are hereby incorporated herein by reference.

Typically, electrochromic mirrors are made with glass elements having athickness of about 2.3 mm. The preferred thin glass elements accordingto the present invention have thicknesses of about 1.0 mm, which resultsin a weight savings of more than 50%. This decreased weight ensures thatthe mechanisms used to manipulate the orientation of an outside mirrorelement, commonly referred to as carrier plates, are not overloaded andfurther provides significant improvement in the vibrational stability ofthe mirror.

Front transparent element 112 may be any material which is thin andtransparent and has sufficient strength to be able to operate in theconditions, e.g., varying temperatures and pressures, commonly found inthe automotive environment. Front element 112 may comprise any type ofglass, borosilicate glass, soda lime glass, float glass or any othermaterial, such as, for example, a polymer or plastic, that istransparent in the visible region of the electromagnetic spectrum. Frontelement 112 is preferably a sheet of glass with a thickness ranging from0.5 mm to about 1.8 mm, preferably from about 0.5 to 1.6 mm, morepreferably from about 0.5 to 1.5, even more preferably from about 0.8 mmto about 1.2 mm, with the presently most preferred thickness about 1.0mm. Rear element 114 should meet the operational conditions outlinedabove, except that it does not need to be transparent, and therefore maycomprise polymers, metals, glass, ceramics, and preferably is a sheet ofglass with a thickness in the same ranges as element 112.

When both glass elements are made thin, the vibrational properties of aninterior or exterior mirror improve—although the effects are moresignificant for exterior mirrors. These vibrations that result from theengine running and/or the vehicle moving affect the rearview mirror,such that the mirror essentially acts as a weight on the end of avibrating cantilever beam. This vibrating mirror causes blurring of thereflected image that is a safety concern as well as a phenomenon that isdispleasing to the driver. As the weight on the end of the cantileverbeam (i.e., the mirror element attached to the carrier plate on theoutside mirror or the mirror mount on the inside mirror) is decreased,the frequency at which the mirror vibrates increases. If the frequencyof the mirror vibration increases to around 60 Hertz, the blurring ofthe reflected image is not visually displeasing to the vehicleoccupants. Moreover, as the frequency at which the mirror vibratesincreases, the distance the mirror travels while vibrating decreasessignificantly. Thus, by decreasing the weight of the mirror element, thecomplete mirror becomes more vibrationally stable and improves theability of the driver to view what is behind the vehicle. For example,an interior mirror with two glass elements having a thickness of 1.1 mmhas a first mode horizontal frequency of about 55 Hertz whereas a mirrorwith two glass elements of 2.3 mm has a first mode horizontal frequencyof about 45 Hertz. This 10 Hertz difference produces a significantimprovement in how a driver views a reflected image.

In the assembly and manufacture of electrochromic devices, polymericbeads may be applied to the electrochromic mirror area on the viewingarea of the second or third surface, i.e., inboard of the perimeterseal, to temporarily maintain proper cell spacing during themanufacturing process. These beads are even more useful with deviceshaving thin glass elements because they help prevent distortion anddouble image during device manufacture and maintain a uniformelectrochromic medium thickness until gellation occurs. It is desirablethat these beads comprise a material that will dissolve in theelectrochromic medium and is benign to the electrochromic system whilebeing compatible with whatever electrochromic system is contained withinthe chamber 125 (e.g., the constituents of gelled layer). While the useof PMMA beads is known, it is not preferred because they have thefollowing disadvantages: they require a heat cycle (generally at least 2hours at 85 degrees C.) to dissolve, they do not dissolve before thepreferred gels of the present invention crosslink, they can cause lightrefracting imperfections in gelled and non-gelled electrochromicdevices, and they can cause the electrochromic medium to color and clearmore slowly near the area where beads were prior to dissolving.

Referring again to FIG. 3A, chamber 125, defined by transparentconductor 128 (disposed on front element rear surface 112 b),reflector/electrode 120 (disposed on rear element front surface 114 a),and an inner circumferential wall 132 of sealing member 116, contains anelectrochromic medium 126. Electrochromic medium 126 is capable ofattenuating light traveling therethrough and has at least onesolution-phase electrochromic material in intimate contact withreflector/electrode 120 and at least one additional electroactivematerial that may be solution-phase, surface-confined, or one thatplates out onto a surface. However, the presently preferred media aresolution-phase redox electrochromics, such as those disclosed inabove-referenced U.S. Pat. Nos. 4,902,108, 5,128,799, 5,278,693,5,280,380, 5,282,077, 5,294,376, and 5,336,448. U.S. Pat. No. 6,020,987,entitled “ELECTROCHROMIC MEDIUM CAPABLE OF PRODUCING A PRE-SELECTEDCOLOR,” discloses electrochromic media that are perceived to be graythroughout their normal range of operation. The entire disclosure ofthis patent is hereby incorporated herein by reference. If asolution-phase electrochromic medium is utilized, it may be insertedinto chamber 125 through a sealable fill port 142 through well-knowntechniques, such as vacuum backfilling and the like.

An electrical circuit (not shown), such as those taught in CanadianPatent No. 1,300,945 and U.S. Pat. Nos. 5,204,778, 5,434,407, and5,451,822, is connected to and allows control of the potential to beapplied across reflector/electrode 120 and transparent electrode 128,such that electrochromic medium 126 will darken and thereby attenuatevarious amounts of light traveling therethrough and thus vary thereflectance of the mirror containing electrochromic medium 126.

FIG. 3B shows a cross-sectional view of a second example of anelectrochromic mirror element 115 b that may be used in mirror assembly110 a. The second embodiment differs from the first embodiment shown inFIG. 3A in that the reflective polarizing “wire grid” is provided on thefourth surface 114 b of the electrochromic mirror element, while anelectrode 176 is provided on third surface 114 a. Electrode 176 may be atransparent conductive material similar to electrode 128 or may betransflective.

Although the two embodiments described above and shown in FIGS. 3A and3B include electrochromic elements 115 a and 115 b, other forms ofelectro-optic elements may also be used, such as an LCD or the like.

FIG. 3C shows a cross-sectional view of another example of a mirrorelement 115 c that may be used in mirror assembly 110 a. Mirror element115 c includes a cholesteric element comprising a first substrate 112, asecond substrate 114 and a seal 116 disposed therebetween. A chamber 125is formed between the substrates. The cholesteric element furthercomprises transparent electrodes 203 and 204 provided on opposingsurfaces of substrates 112 and 114, and orientation layers 205 and 206.A mixture 210 of polymerizable, cholesteric liquid crystalline moleculesare provided within chamber 125. Further details of the construction ofa suitable cholesteric element is disclosed in U.S. Pat. Nos. 5,762,823and 5,798,057, the entire disclosures of which are incorporated hereinby reference.

According to a variation on the above construction using an LCD as amirror element, electrode 203 may be made of a reflective or atransflective material so as to function as a reflector in a similarmanner by which third surface reflectors are used in electrochromicrearview mirrors. Many different metal depositions or combinations ofmultiple depositions can be used to achieve reflection, adhesion,conductivity, chemical compatibility, and windowing capability. One ormore of the following materials can be chosen for deposition on thethird surface in any order that preferably accomplishes one or more ofthe above goals: silver, silver alloys, chromium, ruthenium, palladium,platinum, indium-doped tin oxide (ITO), tin oxide (doped), zinc oxide(doped), aluminum, or SiO₂. Examples of third surface reflectors thatcould be used as electrode 203 are disclosed in U.S. Pat. Nos.6,512,624, 6,356,376, 6,166,848, 6,111,684, 6,064,508, and 5,818,625,the entire disclosures of which are herein incorporated by reference. Itwill be appreciated that this aspect of the present invention may beused with forms of liquid crystalline molecules other than thecholesteric liquid crystalline molecules discussed above, and may bemade with or without a display or other electronic element positionedbehind the LCD element.

FIG. 3D shows a cross-sectional view of another example of a mirrorelement 115 d that may be used in mirror assembly 110 a. Mirror element115 d includes both a cholesteric element and an electrochromic element.The combined structure includes an intermediate substrate 216 that ispositioned between first substrate 112 and second substrate 114 with theelectrochromic element disposed between first substrate 112 andintermediate substrate 216, and the cholesteric element disposed betweenintermediate substrate 216 and second substrate 114. Such a constructionprovides the benefit of a continuous variance in the reflectivity levelof the mirror. The cholesteric element may be constructed as describedabove with respect to FIG. 3C, while the electrochromic element may beconstructed as described above with respect to FIG. 3B with theexception that the fourth surface reflector 174 is not used as thecholesteric element serves as the reflector.

FIG. 3E shows a cross-sectional view of another example of a mirrorelement 115 e that may be used in mirror assembly 110 a. Mirror element115 e includes two cholesteric elements separated by intermediatesubstrate 216. As discussed above, the use of two cholesteric elementsprovides additional states of reflectance/transmittance. The twocholesteric elements are constructed as described above with respect toFIG. 3C.

FIG. 6 shows a rearview mirror assembly 110 b constructed in accordancewith another embodiment of the invention. Rather than using a mirrorelement with a polarized reflector, mirror assembly 110 b uses a mirrorelement 115 f having a reflector with a plurality of small holes orslits that align with the light emitting areas of the display.

FIG. 7A shows a close up of one construction of the mirror element usingholes 300 a formed in reflector 302. FIG. 7B shows a close up of oneconstruction of the mirror element using slits 300 b formed in reflector302.

FIG. 8A shows a partial cross-sectional view of mirror element 115 f. Asshown, mirror element 115 f closely resembles mirror element 115 b shownin FIG. 3B. Mirror element 115 f differs, however, that in place ofpolarized reflector 174, a reflector 302 is provided that includes aplurality of holes 300 a and/or slits 300 b as shown in FIGS. 7A and 7B.As shown in FIG. 9A, the holes and slits (collectively referred to as“apertures 300”) are sized and positioned to match the size and positionof the light emitting areas 304 of display 170 and are aligned therewithso that light from the display can be emitted through apertures 300unimpeded by reflector 302.

FIGS. 9B and 9C show a variation on the construction shown in FIG. 9A,whereby the front surface of display 170 is coated with a reflectivelayer 306 except in the light emitting areas 304. As shown in FIG. 9B,the light from the display 170 may still be emitted without interferencefrom reflective layer 306 or reflector 302. To better hide the displayand improve reflectivity of mirror element 115 f when display 170 is notactivated, an actuator 308 is provided that shifts display 170 relativeto mirror element 115 f such that the light emitting areas 304 ofdisplay 170 no longer align with apertures 300 in reflector 302. Thiscauses the reflective layer 306 on display 170 to align with apertures300 so that any light from the front of the mirror that passes throughapertures 300 will be reflected by reflective layer 306.

FIG. 9D shows another variation on the construction shown in FIG. 9A.Specifically, this construction differs in that a transflective (i.e.,partially transmissive, partially reflective) layer 310 is coated overreflector 302 and within apertures 300 so that much of the light fromlight emitting areas 304 may still pass through apertures 300, whilemost of the light from the front of the mirror that would otherwise passthrough apertures 300 will be reflected by transflective layer 310.

FIG. 8B shows a variation on the construction of mirror element 115 fshown in FIG. 8A. In this variation, an optical device 320 is providedbetween display 170 and reflector 302 that includes a plurality oflenses 322 each corresponding and aligned with a light emitting area 304of display 170. As discussed above, by providing such an optical device320, the lenses 322 may cause the normally divergent light emitted fromlight emitting areas 304 of display 170 to converge and then diverge. Byselecting an appropriate lens power for lenses 322 and by appropriatepositioning of apertures 300 relative to lenses 322, the light fromdisplay may be caused to converge to a small point of light where itpasses through apertures 300 and then diverge after passing throughapertures 300. This allows for the apertures 300 to be made evensmaller.

FIG. 8C shows a modification to the construction shown in FIG. 8Cwhereby reflector 320 is provided on the third surface 114 a of mirrorelement 115 f, which is preferably an electrochromic mirror element.Additionally, the lens power of lenses 322 are adjusted to accommodate agreater distance to apertures 300, which are now on the opposite side ofsubstrate 114.

FIG. 10 discloses an electrical block diagram of an exemplary rearvision system for use in a vehicle. As shown, a camera 426 is coupled toa controller 430, which in turn is coupled to a display system 432 (thatincludes display 170). Camera 426 is mounted to the vehicle so as tocapture an image to the rear of the vehicle. Controller 430 receives thecamera images as well as input from an ambient sensor 434, a directglare sensor 436, and a manual intensity adjustment mechanism 416 andgenerates a display signal for the display system 426 using theseinputs. A detailed description of the preferred operation of such a rearvision system is disclosed in commonly assigned U.S. Patent ApplicationPublication No. US 2003/0103141 A1, the entire disclosure of which isincorporated herein by reference.

As discussed herein, the display 170 is preferably located in rearviewmirror assembly 110. The width to height aspect ratio of the image thatis recorded and presented on typical video image display and camerasystems is 4 to 3 (1.33 to 1) or 16 to 9 (1.78 to 1). This aspect ratiois not ideal for a display located in the interior mirror position of avehicle. To display an image that is the full width of mirrors invehicles today the display image would be between about 6 to 14 incheswide. If the height aspect ratio of a typical camera/video display weremaintained the height of these mirrors would range from about 3.5 to 12inches. The height of the reflective surface in a typical rearviewmirror ranges from about 2 inches to about 3 inches. If the mirror ismuch higher it will begin to significantly block the forward view in avehicle. This is a significant safety concern. It is therefore desirableto have a width to height aspect ratio of display 170 and camera 426that is between 2 to 1 and 12 to 1 and more preferable to have andaspect ratio of the display and camera that has an aspect ratio between3 to 1 and 6 to 1 and most preferable to have a display and camerasystem with an aspect ratio between 4 to 1 and 5 to 1.

Although the above described embodiments have focused on the use of avideo display 170, the above described mirror elements 115 a, 115 b, 115c, 115 d, and 115 e may also be used with other forms of displays andwith light sources and light sensors. As shown in FIG. 5, for example, arearview mirror assembly 110 b may include one or more alphanumericdisplay 145 a and 145 b. Such displays may be configured to emitpolarized light through the reflective polarizer 174 of the mirrorelement 115. Such displays may be of any conventional form and arepreferably LCDs. The displays may also include indicia panels of thetype disclosed in commonly assigned U.S. Pat. Nos. 6,572,233 and6,356,376, the entire disclosures of which are incorporated herein byreference. Such indicia type displays may, for example, display vehicleheading and information relating to the enablement status of apassenger-side inflatable restraint system.

When the display(s) positioned behind the mirror element are smallerthan the area of the mirror element, it is possible to construct themirror element such that the reflective polarizer 174 is disposed onlyin front of the display such that the mirror element as a whole has ahigher level of reflectance.

In addition to the foregoing structure, the various techniques disclosedin commonly assigned U.S. Pat. Nos. 6,356,376 and 6,700,692, the entiredisclosures of which are incorporated herein by reference, to increasethe contrast of the display may be used in conjunction with the abovedisclosed mirror elements.

Other approaches could be used to increase the contrast of the display(alphanumeric, video, or high resolution type). When maximum contrast isdesired, such as when using the camera/display system to back up avehicle, the transflective mirror could be tilted, for example, as in aprismatic mirror such that the high reflectivity mirror surface imagesthe reflection of the darker vehicle roof or other area of the vehiclethat is not “bright.” In this way, the display would not compete withthe light directly transmitted through the mirror window. Also, anotherapproach that would remove the mirror completely from the display lightpath would be to hinge the mirror at the top (or bottom) and flip it outof the way as shown in FIG. 11A. For instance, if the transflective oropaque electro-optic mirror element 115 a, 115 b, 115 c, 115 d, 115 e,or 115 f (collectively referred to as “115”) were hinged at the top of abezel 32, the mirror element 115 could be flipped up so that it isperpendicular to a mirror housing 30 so that an unobstructed view of thevideo display 170 could be seen.

This could be done manually or automatically when needed such as whenthe vehicle is put in reverse. The inside surface around the videodisplay 170 and the back of the flipped-up mirror element 115 could beblack or dark in color to shield the display from ambient light andimprove contrast. Side shields could also be added and/or the display170 could be recessed in the mirror housing to further enhance contrast.The “flipped up” mirror element 115 would not block the driver field ofview as in prior art where the display is flipped down or pulled downbelow the mirror assembly. When flipped down, as shown in FIG. 11B, themirror element 115 could be used in the conventional manner.

FIGS. 12A and 12B show a variation on the embodiment shown in FIGS. 11Aand 11B. In this variation, display 170 is pivotally attached to themirror housing 30 instead of mirror element 115. Display 170 may also bemoveably attached to housing 30 so as to be moved linearly outside orfrom within housing 30. In the particular example illustrated in FIGS.12A and 12B, display 170 pivots from the bottom of mirror housing 30backward behind the housing when not in use, and pivots downward belowthe mirror housing when in use. The display could be mounted elsewhereand flipped or slid up or down to be visible in various locationsrelative to the mirror housing. The display 170 could be automaticallypivoted into a viewable position when, for example, the vehicle is putin reverse. The display could then be manually pushed back into a stowedposition. Such an arrangement would allow for a relatively simpleactuator mechanism to be used such as a mechanism including a biasedlatch that catches and holds the display support in a stowed positionand releases the support when the vehicle is placed in reverse. It willbe appreciated, however, that the display 170 may be automatically movedto the stowed position when the vehicle is placed in any gear other thanreverse. Alternatively or additionally, an alarm signal may sound whenthe vehicle changes gear and the display is not in the proper positionin order to prompt the driver to manually reposition the display 170.The display 170 may further be spring-assisted and or use an inertiagear to provide for a more deliberate and steady rate of movement.

It will further be appreciated that the mirror element structurediscussed above may be used for outside mirror assemblies 111 a and 111b having one or more light sources serving as turn signal light displays145 c. Further, various other light sources may be provided in anoutside mirror assembly, which may be polarized so as to beadvantageously combined with the mirror elements discussed above.

The present invention has been described as rearview assembliesincorporating particular forms of variable reflectivity mirrors incombination with displays. It will be appreciated by those skilled inthe art that various other vehicle accessories and components may beincorporated in the rearview mirror assembly in whole or in part and invarious combinations. Such vehicle accessories and components may bemounted within, on or to the mirror housing, the mirror mount, anattachment to the mirror mount or housing, or in a console or otherhousing associated with the rearview mirror assembly. Additionally, anysuch vehicle accessories may share components with one another, such asprocessors, sensors, power supplies, wire harnesses and plugs, displays,switches, antennae, etc. Examples of other vehicle accessories,components or features are described further below.

FIGS. 13A-13C show another embodiment of a rearview mirror assembly 110c in which any of the above described mirror elements 115 isincorporated. As illustrated in FIGS. 13A-13C, mirror assembly 900 acomprises a bezel 902 and a case 904. The bezel and the case combine todefine the mirror housing for incorporation of features in addition to areflective element 115 and information displays 905 a and 905 b.Commonly assigned U.S. Pat. Nos. 6,102,546, D410,607, 6,407,468,6,420,800, and 6,471,362, the disclosures of which are incorporated intheir entireties herein by reference, describe examples of variousbezels, cases and associated button construction that may be used withthe present invention.

As depicted in FIGS. 13A-13C, mirror assembly 110 c may comprise firstand second microphones 910 a and 910 b. Examples of microphones for usewith the present invention are described in commonly assigned U.S.patent application Ser. No. 09/444,176, U.S. Pat. Nos. 6,614,911 and6,882,734, and PCT Application No. PCT/US02/32386, the disclosures ofwhich are incorporated in their entireties herein by reference. Althoughthe two microphones are shown as being mounted to the backside of mirrorcase 904, one or more such microphones may be mounted on the top of themirror assembly (as shown in FIGS. 14A and 14B), on the bottom of themirror assembly, or any where within the mirror case or bezel.Preferably, two microphones 910 a and 910 b are incorporated, one neareach end, into the mirror assembly on the backside of the mirror casewithin recessed portions 912 a and 912 b. As shown in FIG. 13A, themicrophones are constructed with an acoustic dam 914 extending aroundtransducer 916 within microphone housing 918. Additional details of thispreferred construction are disclosed in commonly-assigned InternationalPCT Application No. PCT/US02/32386, the entire disclosure of which isincorporated herein by reference. The audio systems including themicrophones may be integrated, at least in part, in a common controlwith information displays and/or may share components with theinformation displays. In addition, the status of these systems and/orthe devices controlled thereby may be displayed on the associatedinformation displays.

As shown in FIGS. 14A and 14B, a single microphone 910 is provided onthe top side of the mirror assembly 110 d. In this construction, it ispreferable to include two transducers in microphone housing 918 in amanner similar to that disclosed in the above-referenced InternationalPCT Application No. PCT/US02/32386 and U.S. Pat. No. 6,882,734.

Mirror assembly 110 c, 110 d may include first and second illuminationassemblies 920 a and 920 b. Various illumination assemblies andilluminators for use with the present invention are described incommonly assigned U.S. Pat. Nos. 5,803,579, 6,335,548, 6,441,943,6,521,916, 6,523,976, 6,670,207, and 6,805,474, as well as, commonlyassigned U.S. patent application Ser. No. 09/723,675, the disclosures ofwhich are incorporated in their entireties herein by reference. Eachillumination assembly preferably comprises a reflector, a lens and anilluminator (not shown). There may be two illumination assembliesgenerally positioned to illuminate a front passenger seat area and thesecond generally positioned to illuminate a driver seat area.Alternatively, there may be only one illumination assembly thatilluminates both seat areas and/or there may be additional illuminatorassemblies such as one to illuminate a center console area, overheadconsole area or an area between the front seats.

Mirror assembly 110 c, 110 d may also include first and second switches922 a and 922 b. Suitable switches for use with the present inventionare described in detail in commonly assigned U.S. Pat. Nos. 6,407,468,6,420,800, 6,426,568, 6,614,579, and 6,471,362, the disclosures of whichare incorporated in their entireties herein by reference. These switchesmay be incorporated to control the illumination assemblies, thedisplays, the mirror reflectivity, a voice activated system, a compasssystem, a telephone system, a highway toll booth interface, a telemetrysystem, a headlight controller, a rain sensor, a tire pressuremonitoring system, a navigation system, a lane departure warning system,an adaptive cruise control system, etc. Any other display or systemdescribed herein or within the references incorporated by reference maybe incorporated in any location within the associated vehicle and may becontrolled using the switches.

Mirror assembly 110 c, 110 d may also include first and secondindicators 924 a and 924 b. Various indicators for use with the presentinvention are described in commonly assigned U.S. Pat. Nos. 5,803,579,6,335,548, 6,441,943, 6,521,916, 6,523,976, 6,670,207, and 6,805,474, aswell as, commonly assigned U.S. patent application Ser. No. 09/723,675,the disclosures of which are incorporated in their entireties herein byreference. These indicators may indicate the status of the displays, themirror reflectivity, a voice activated system, a compass system, atelephone system, a highway toll booth interface, a telemetry system, aheadlight controller, a rain sensor, a security system, etc. Any otherdisplay or system described herein or within the references incorporatedby reference may be incorporated in any location within the associatedvehicle and may have a status depicted by the indicators.

Mirror assembly 110 c, 110 d may further include first and second lightsensors 926 and 928 serving as glare and ambient sensors, respectively.Preferred light sensors for use within the present invention aredescribed in detail in commonly assigned U.S. Pat. Nos. 5,923,027,6,313,457, 6,359,274, 6,379,013, 6,402,328, 6,679,608, and 6,831,268,the entire disclosures of which are incorporated herein by reference.The glare sensor 926 and/or ambient sensor 928 automatically control thereflectivity of a self dimming reflective element as well as theintensity of information displays and/or backlighting. The glare sensor926 may also be used to sense headlights of trailing vehicles and theambient sensor is used to detect the ambient lighting conditions thatthe system is operating within. In another embodiment, a sky sensor 930may be incorporated positioned to detect light levels generally aboveand in front of an associated vehicle. The sky sensor 930 may be used toautomatically control the reflectivity of a self-dimming element, theexterior lights of a controlled vehicle and/or the intensity ofinformation displays. The mirror assembly may further include sun-loadsensors for sensing light levels towards the driver side and passengerside of the vehicle so as to control the climate control system of thevehicle.

Additionally, mirror assembly 110 c, 110 d may include first, second,third, fourth and fifth operator interfaces 932 a-932 e located inmirror bezel 902. Each operator interface is shown to comprise a backlitinformation display “A,” “AB,” “A1,” “C,” and “12”. It should beunderstood that these operator interfaces can be incorporated any wherein the associated vehicle, for example, in the mirror case, accessorymodule, instrument panel, overhead console, dash board, seats, centerconsole, etc. Suitable switch construction is described in detail incommonly assigned U.S. Pat. Nos. 6,407,468, 6,420,800, 6,426,568,6,614,579, and 6,471,362, the disclosures of which are incorporated intheir entireties herein by reference. These operator interfaces maycontrol the illumination assemblies, the displays, the mirrorreflectivity, a voice activated system, a compass system, a telephonesystem, a highway toll booth interface, a telemetry system, a headlightcontroller, a rain sensor, a tire pressure monitoring system, anavigation system, a lane departure warning system, an adaptive cruisecontrol system, etc. Any other display or system described herein orwithin the references incorporated by reference may be incorporated inany location within the associated vehicle and may be controlled usingan operator interface or interfaces. For example, a user may program adisplay or displays to depict predetermined information or may program adisplay or displays to scroll through a series of information, or mayenter set points associated with certain operating equipment withassociated sensor inputs to display certain information upon theoccurrence of a given event. In one embodiment, for example, a givendisplay may be in a non-illuminated state until the engine temperatureis above a threshold, the display then automatically is set to displaythe engine temperature. Another example is that proximity sensorslocated on the rear of a vehicle may be connected to a controller andcombined with a display in a rearview mirror to indicate to a driver thedistance to an object; the display may be configured as a bar that has alength proportional to the given distance.

Further, mirror assembly 110 c, 110 d may include an electronic compasssystem within the mount or mirror housing of a rearview mirror assembly.Examples of such electronic compass systems are disclosed in commonlyassigned U.S. Pat. No. 6,140,933 and commonly assigned U.S. PatentApplication Publication Nos. US 2003/0167121 A1, US 2004/0236510 A1, andUS 2004/0254727 A1, the entire disclosures of which are incorporatedherein by reference.

Although specific locations and numbers of these additional features aredepicted in FIGS. 15A-15C and 16A and 16B, it should be understood thatfewer or more individual devices may be incorporated in any locationwithin the associated vehicle and as described within the referencesincorporated herein.

A mirror mount 903 is included for mounting the mirror assembly within avehicle either to windshield 898, or to the vehicle roof structure. Itshould be understood that a host of accessories may be incorporated intothe mount 903 or into a housing 952 attached to mount 903 such as a rainsensor, a camera, a headlight control, an additional microprocessor,additional information displays, compass sensors, etc. These systems maybe integrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays.

Mirror assembly 110 c is shown in FIG. 15A to further comprise a circuitboard 960 on which the compass sensor module (not shown) may be mounted,and a daughter board 962 with an input/output bus interface (not shown).

The electrical output signal from either, or both, of the sensors 926and 928 may be used as inputs to a controller (not shown) to control thereflectivity of reflective element 901 and, or, the intensity of any oneor all of the displays 905 a and 905 b. The details of various controlcircuits for use herewith are described in commonly assigned U.S. Pat.Nos. 5,883,605, 5,956,012, 6,084,700, 6,222,177, 6,224,716, 6,247,819,6,249,369, 6,392,783 and 6,402,328, the disclosures of which areincorporated in their entireties herein by reference. These systems maybe integrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays.

Although the compass sensor module may be mounted to circuit board 960,it should be understood that the sensor module may be located withinmount 903, an accessory module 952 positioned proximate mirror assembly110 c or at any location within an associated vehicle such as under adash board, in an overhead console, a center console, a trunk, an enginecompartment, etc. The above described compass systems may be integrated,at least in part, in a common control with information displays and/ormay share components with the information displays. In addition, thestatus of these systems and/or the devices controlled thereby may bedisplayed on the associated information displays.

Circuit board 960 may comprise a controller (not shown), such as amicroprocessor, and daughter board 962 may comprise an informationdisplay 905 a. The microprocessor may, for example, receive signal(s)from the compass sensor module and process the signal(s) and transmitsignal(s) to the daughter board to control display 905 a to indicate thecorresponding vehicle heading. As described herein and within thereferences incorporated by reference herein, the controller may receivesignal(s) from light sensor(s), rain sensor(s) (not shown), automaticvehicle exterior light controller(s) (not shown), microphone(s), globalpositioning systems (not shown), telecommunication systems (not shown),operator interface(s) and a host of other devices, and control theinformation display(s) to provide appropriate visual indications.

The controller (or controllers) used to control the rear vision systemand or the reflectivity of the mirror element, at least in part, controlthe mirror reflectivity, exterior lights, rain sensor, compass,information displays, windshield wipers, heater, defroster, defogger,air conditioning, telephone system, navigation system, security system,tire pressure monitoring system, a garage door opening transmitter,remote keyless entry, telemetry systems, voice recognition systems suchas digital signal processor based voice actuation systems, and vehiclespeed. The controller 430 (or controllers) may receive signals fromswitches and or sensors associated with any of the devices describedherein and in the references incorporated by reference herein toautomatically manipulate any other device described herein or describedin the references included by reference. The controller may be, at leastin part, located outside the mirror assembly or may comprise a secondcontroller elsewhere in the vehicle or additional controllers throughoutthe vehicle. The individual processors may be configured to communicateserially, in parallel, via BLUETOOTH™ protocol, wireless communication,over the vehicle bus, over a CAN bus or any other suitablecommunication. A multi-pin connector interface 964 may be provided forsuch external connections.

Exterior light control systems as described in commonly assigned U.S.Pat. Nos. 5,990,469, 6,008,486, 6,130,421, 6,130,448, 6,255,639,6,049,171, 5,837,994, 6,403,942, 6,281,632, 6,291,812, 6,469,739,6,465,963, 6,429,594, 6,587,573, 6,611,610, 6,621,616, 6,653,614,6,379,013, 6,861,809, and 6,774,988, and U.S. Provisional PatentApplication Nos. 60/404,879 and 60/394,583, the disclosures of which areincorporated in their entireties herein by reference, may beincorporated in accordance with the present invention. These systems maybe integrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays. Asdisclosed in U.S. Pat. No. 6,587,573, both the compass sensors and theimaging sensor array 950, may be housed in an accessory housing 952attached to mount 903.

Moisture sensors and windshield fog detector systems are described incommonly-assigned U.S. Pat. Nos. 5,923,027, 6,617,564, 6,681,163, and6,313,457, the disclosures of which are incorporated in their entiretiesherein by reference. These systems may be integrated, at least in part,in a common control with information displays and/or may sharecomponents with the information displays. In addition, the status ofthese systems and/or the devices controlled thereby may be displayed onthe associated information displays.

Commonly assigned U.S. Pat. No. 6,262,831, the disclosure of which isincorporated herein by reference in its entirety, describes powersupplies for use with the present invention. These systems may beintegrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays.

The mirror assembly may further include one or more antennae 940 forreceipt and/or transmission of RF signals. Appropriate receiving,transmitting, and/or processing circuitry may further be included in orattached to the mirror assembly. Such antennae may be used for acellular telephone system, a BLUETOOTH™ transmitting/receiving system, aremote keyless entry (RKE) system, a trainable garage door openersystem, a tire pressure monitoring system, a global positioningsatellite system, a LORAN system, etc. Some of these systems may share acommon antenna and receiving, transmitting, processing, and displaycircuits where appropriate. Examples of a tire pressure monitoringsystem incorporated in a rearview mirror assembly are disclosed incommonly assigned U.S. Pat. Nos. 6,215,389, 6,431,712, 6,861,942, and6,696,935, the entire disclosures of which are incorporated herein byreference. Examples of a GPS system incorporated in a rearview mirrorassembly are disclosed in commonly assigned U.S. Pat. Nos. 6,166,698,6,297,781, 6,396,446, and in U.S. Patent Published Application No. US2002/0032510 A1, the entire disclosures of which are incorporated hereinby reference. An example of a LORAN system incorporated in a rearviewmirror assembly is disclosed in commonly assigned U.S. Pat. No.6,539,306, the entire disclosure of which is incorporated herein byreference. An example of both telephone/telematics system and aBLUETOOTH™ system incorporated in a rearview mirror assembly isdisclosed in commonly assigned U.S. Patent Application No. US2002/0032510 A1, the entire disclosure of which is incorporated hereinby reference. Examples of a trainable garage door opening systems andRKE systems incorporated in a rearview mirror assembly are disclosed inU.S. Pat. No. 6,091,343, the entire disclosures of which areincorporated herein by reference.

The mirror may further include an infrared (IR) transmitter/receiver fortransmitting/receiving information to and from the mirror assembly andpossibly to and from the vehicle. An example of such a rearview mirrorassembly is disclosed in commonly-assigned U.S. Pat. No. 6,407,712, theentire disclosure of which is incorporated herein by reference.

The mirror assembly may further include one or more of the same ordifferent types of displays. Examples of different types of displaysinclude vacuum fluorescent, LCD, reverse LCD, LED, organic LED, dotmatrix, backlit indicia, etc. For displays intended to simultaneouslydisplay significant amounts of information, the display disclosed incommonly-assigned U.S. Pat. No. 6,346,698 may be used. The entiredisclosure of which is incorporated herein by reference. Examples ofbacklit indicia panel displays are disclosed in commonly-assigned U.S.Pat. Nos. 6,170,956, 6,572,233, 6,870,655, and 6,356,376, the entiredisclosures of which are incorporated herein by reference. Variousdisplays used in rearview mirrors are disclosed in commonly-assignedU.S. Pat. Nos. 6,356,376 and 6,700,692, the entire disclosures of whichare incorporated herein by reference.

The wiring for the vehicle accessories in the rearview mirror assemblyhousing may be run through the mounting bracket and along the windshield(if the mounting bracket does not already extend to the headliner) undera channel mount. An example of a rearview mirror assembly in which thewiring for accessories in the mirror assembly housing are routed throughthe mounting bracket is disclosed in commonly-assigned U.S. Pat. No.6,467,919, the entire disclosure of which is incorporated herein byreference.

While the present invention has been described as being implemented withthe sensors positioned within the housing of a rearview mirror assembly,the sensors could be mounted in the mounting foot or in any otherlocation of the rearview mirror assembly. Further still, any or all ofthe various components of the inventive electronic compass may bemounted elsewhere in the vehicle. It will be further appreciated thatcertain embodiments of the present invention are novel and useful invehicles such as land-based vehicles (i.e., automobiles, trucks, sportutility vehicles (SUVs), trains, motorcycles, bicycles, mopeds,scooters, snowmobiles, all-terrain vehicles (ATVs), military vehicles)as well as in other vehicles such as airplanes, marine vessels, andamphibious vehicles.

The switchable variable pitch cholesteric reflective polarizersdescribed above can also be used in windows, sunroofs and skylightswhere their switchable reflective properties have advantages overelectrochromic devices in similar applications. Electrochromic window,sunroof or skylight devices attenuate light by absorbing it. As a directresult of absorbing this light or energy the temperature of theelectrochromic device increases. The temperature rise can be substantial(+50° C. above ambient temperatures). The electrochromic window, sunroofor skylight will dissipate this heat by radiation and/or conduction andif this heat is transferred into the structure or vehicle incorporatingthe electrochromic device it will tend to reduce the energy efficiencyand creature comfort these devices are intended to provide. Higherelectrochromic device operating temperatures can also shorten usabledevice life.

A window, sunroof or skylight constructed from one or two switchablevariable pitch reflective polarizer(s) would reflect and not absorblight and therefore would not get as hot as an electrochromic device ina similar application. The mode of operation of one switchable variablepitch cholesteric reflective polarizer would be either to reflect onetype of polarization and transmit the other or transmit both types ofpolarization. Two switchable variable pitch cholesteric polarizers couldbe configured to reflect both types of polarization, reflect one type ofpolarization and transmit the other or transmit both types ofpolarization.

The wavelength range of radiation that is reflected or transmitted canbe tuned by adjusting pitch of the cholesteric structure. Low E coatingson glass typically used in the window industry reflect wavelengths oflight greater than 2400 nm and have high transmission in the visiblerange. In window, sunroof and skylight applications it is desirable toswitchably attenuate the remaining visible (400 nm to 800 nm) and nearinfrared (IR) light (800 nm to 2400 nm). It is also desirable toswitchably attenuate visible light and IR light separately. This can beachieved with one or more switchable variable pitch cholestericreflective polarizers by adjusting the mean pitch length and reflectiveband width of the variable pitch cholesteric media. One could configurea single variable pitch cholesteric reflective polarizer with a widebandwidth to reflect visible and IR light or stack two or more variablepitch cholesteric reflective polarizers with different mean pitchlengths to selectively reflect in the visible or IR or both.

It is sometimes desirable in architectural or vehicle applications tohave windows, sunroofs or skylights that are colored. This can also beachieved with variable pitch cholesteric reflective polarizers by againadjusting the mean pitch and range of pitch in the cholesteric media toselectively reflect and transmit different wavelengths or colors oflight. As the voltage applied across the cholesteric media is increasedthe cholesteric pitch structure begins to unwind (pitch increases) asmore liquid crystal molecules begin to align with the applied field.This voltage induced pitch change can change the reflected bandwidth andshift the mean wavelength of light that is reflected resulting in acolor change and/or a shift in reflection from the visible to the IR.

In window, sunroof and skylight applications it is often not desirableto have specular reflection of light in the high reflectance mode.Switchable variable pitch cholesteric media can be made to diffuselyreflect light if the direction of pitch varies. This can be accomplishedfor instance by roughening one or both substrate surface(s) or addingparticles such as glass or plastic spheres, flakes or other shapes ofpreferably transparent solid media to the variable pitch cholestericlayer.

To align the liquid crystal molecules in a preferred direction thedevice substrate(s) and/or cholesteric media spheres of particulatefiller(s) can be surface treated with materials such as amino silane oroctadecyl silane to promote either homogeneous (parallel) or homeotropic(perpendicular) alignment or both to generate a diffuse scatteringreflective texture. The substrates may be treated with a polymer such asa polyimide, polyvinyl alcohol or polyamideimide with an unidirectionalorientation (achieved by rubbing or other means) to align the liquidcrystal molecules in a preferred direction with a preferred tilt anglerelative to the substrate surface. Preferably such a device would be lowin haze in the high transmission state and diffusely reflective in thehigh reflection state.

The switchable variable pitch cholesteric reflective polarizersdescribed in U.S. Pat. Nos. 5,762,823 and 5,798,057 have another majoradvantage when used in window applications relative to the typicalliquid crystal device and liquid containing electrochromic elements inthat the cholesteric media is a non-flowing solid or free standing gel.Windows are generally mounted in a vertical orientation and if thecholesteric media were in a liquid or flowing gel form the device wouldtend to develop thick spots near the bottom due to hydrostatic pressure.This problem may be overcome using the teachings disclosed in commonlyassigned U.S. Pat. No. 5,940,201 entitled “ELECTROCHROMIC MIRROR WITHTWO THIN GLASS ELEMENTS AND A GELLED ELECTROCHROMIC MEDIUM,” filed onApr. 2, 1997. The entire disclosure of this patent is incorporatedherein by reference.

FIG. 15 shows a first embodiment of a window 1000 constructed inaccordance with the present invention. Window 1000 comprises a frame1002, a first transparent substrate 1012, and a second transparentsubstrate 1014, which serve as the substrates for a cholesteric element1020. Cholesteric element 1020 has first and second transparentelectrodes 1023 and 1024 provided on respective substrates 1012 and1014. In addition, cholesteric element 1020 includes orientation layers1025 and 1026 provided on respective transparent electrodes 1023 and1024 and a seal 1027. A mixture 1030 of polymerizable, cholestericliquid crystalline molecules are provided within chamber 1028. Furtherdetails of the construction of a suitable cholesteric element isdisclosed in U.S. Pat. Nos. 5,762,823 and 5,798,057, the entiredisclosures of which are incorporated herein by reference.

FIG. 16 shows a first embodiment of an insulated window 1100 constructedin accordance with the present invention. Insulated window 1100 includesa frame 1111, two outer panes 1112 and 1114 with a cholesteric element1020 provided therebetween. Preferably, the pane 1112 facing the outsideenvironment serves as a substrate for cholesteric element 1020. Theother substrate 1132 is spaced from pane 1114 to provide a sealedchamber 1135 therebetween. Chamber 1135 may be filled with in insulatinggas such as argon or the like. The window 1100 further includes an outerseal 1115 that seals chamber 1135 and that acts as a spacer.

FIG. 17 shows a second embodiment of an insulated window 1100 aconstructed in accordance with the present invention. Insulated window1100 a is similar to insulated window 1100 except that a secondcholesteric element 1020 a is provided between panes 1112 and 1114. Thisprovides the benefits discussed above. In this embodiment, the first andsecond cholesteric elements are adjacent one another and share substrate1132.

FIG. 18 shows a third embodiment of an insulated window 1100 bconstructed in accordance with the present invention. Insulated window1100 b is similar to insulated window 1100 a except that the secondcholesteric element 1020 a is provided adjacent pane 1114 such that pane1114 acts as one of the substrates for element 1020 a. The insulatedchamber 1035 is thus provided between cholesteric elements 1020 and 1020a. It will be appreciated that for some applications, it may bebeneficial to replace the second cholesteric element 1020 a with anelectrochromic element to provide heat absorption and radiation duringwinter months.

FIG. 19 shows a vehicle window/sunroof 1200 comprising a cholestericelement 1020 and a shatterproof transparent substrate 1212, which may bemade of polyvinylbutrate (PVB), or the like. Cholesteric element 1020may be provided on either the inside or outside of substrate 1212.

U.S. Pat. Nos. 6,239,898, 6,594,065, 6,407,847, 6,594,067, 6,671,080,6,842,276, 6,567,708, 6,597,489, 6,045,643, and 5,805,330 disclosevarious other aspects relating to electro-optic windows that may beincorporated in any of the window embodiments described herein. Theentire disclosures of which are incorporated herein by reference.

The above description is considered that of the preferred embodimentsonly. Modifications of the invention will occur to those skilled in theart and to those who make or use the invention. Therefore, it isunderstood that the embodiments shown in the drawings and describedabove are merely for illustrative purposes and not intended to limit thescope of the invention, which is defined by the following claims asinterpreted according to the principles of patent law, including thedoctrine of equivalents.

1. A variable reflectance mirror element for use in a rearview mirrorassembly having an electronic device positioned behind the mirrorelement for transmitting or receiving light of a first polarization, themirror element comprising: a first substrate having first and secondsurfaces; a second substrate having third and fourth surfaces, thesecond and first substrates positioned in a spaced-apart relationshipsuch that the second and third surfaces face each other; a firstelectrode carried on a surface of the first substrate; a secondelectrode carried on a surface of the second substrate, anelectrochromic medium provided between the first and second substrates;and a reflective polarizer for substantially transmitting light of afirst polarization and substantially reflecting light of a secondpolarization, the second polarization being opposite the firstpolarization, the reflective polarizer disposed on or near the secondsubstrate such that the electronic device transmits or receives light ofthe first polarization through the reflective polarizer, wherein thereflective polarizer includes multiple layers of plastic film.
 2. Avariable reflectance mirror element according to claim 1, wherein thereflective polarizer is laminated to the second substrate proximate thethird surface.
 3. A variable reflectance mirror element according toclaim 1, wherein the reflective polarizer is laminated to the secondsubstrate proximate the fourth surface.
 4. A variable reflectance mirrorelement according to claim 1, wherein the reflective polarizer islaminated to the electronic device.
 5. A variable reflectance mirrorelement according to claim 1, wherein the electronic device is a liquidcrystal display.
 6. A variable reflectance mirror element according toclaim 1, further comprising a switchable cholesteric element including acholesteric medium, the switchable cholesteric element disposed betweenthe electro-optical medium and the electronic device.
 7. A variablereflectance mirror element according to claim 6, wherein the mirrorelement is characterized by a reflectivity that can be set to anyspecified value within a range.
 8. A variable reflectance mirror elementaccording to claim 6, wherein the mirror element is characterized by atleast three discrete states of reflectivity.
 9. A variable reflectancemirror element according to claim 1, wherein the cholesteric medium ischaracterized by a variable pitch.
 10. A variable reflectance mirrorelement according to claim 1, the mirror element configured within arearview mirror assembly further comprising at least one device selectedfrom the group consisting of an interior illumination assembly, anexterior light control, a moisture sensor, an information display, alight sensor, a blind spot indicator, a turning signal indicator, anapproach warning, an operator interface, a compass, a temperatureindicator, a voice actuated device, a microphone, a dimming circuitry, aGPS device, a telecommunication system, a navigation aid, a lanedeparture warning system, an adaptive cruise control, a vision system, arear vision system and a tunnel detection system.
 11. A variablereflectance mirror element according to claim 10, wherein an overallreflection, by the mirror element, of light incident on the firstsurface is at least sixty percent.
 12. A variable reflectance elementaccording to claim 1, wherein the mirror element is characterized by atransmittance that is a function of voltage applied between the firstand second electrodes.
 13. A variable reflectance mirror element for usein a rearview mirror assembly having an electronic device positionedbehind the mirror element for transmitting or receiving light of a firstpolarization, the mirror element comprising: a first substrate havingfirst and second surfaces; a second substrate having third and fourthsurfaces, the second and first substrates positioned in a spaced-apartrelationship such that the second and third surfaces face each other; afirst electrode carried on a the first substrate; a second electrodecarried on the second substrate, an electrochromic medium providedbetween the first and second substrates; and a reflective polarizer forsubstantially transmitting light of a first polarization andsubstantially reflecting light of a second polarization, the secondpolarization being opposite the first polarization, the reflectivepolarizer disposed on or near the second substrate such that theelectronic device transmits or receives light of the first polarizationthrough the reflective polarizer, the reflective polarizer laminated tothe second substrate.
 14. A variable reflectance mirror elementaccording to claim 13, wherein the reflective polarizer is laminated tothe third surface.
 15. A variable reflectance mirror element accordingto claim 13, wherein the reflective polarizer is laminated to the fourthsurface.
 16. A variable reflectance mirror element according to claim13, wherein the reflective polarizer comprises multiple layers ofplastic film.
 17. A variable reflectance mirror element according toclaim 13, wherein the reflective polarizer includes a wire-gildpolarizer.
 18. A variable reflectance mirror element according to claim13, wherein the electronic device is a liquid crystal display.
 19. Avariable reflectance mirror element according to claim 18, wherein theliquid crystal display is a video display.
 20. A variable reflectancemirror element according to claim 18, wherein an area of the liquidcrystal display is substantially equal to a viewing area of the variablereflectance mirror element.
 21. A variable reflectance mirror elementaccording to claim 18, wherein the liquid crystal display ischaracterized by a width between 6 and 14 inches and a width-to-heightratio between 2:1 and 12:1.
 22. A variable reflectance mirror elementaccording to claim 21, wherein the width-to-height ratio of the liquidcrystal display is between 3:1 and 6:1.
 23. A variable reflectancemirror element according to claim 21, wherein the width-to-height ratioof the liquid crystal display is between 4:1 and 5:1.
 24. A variablereflectance mirror element according to claim 18, wherein the liquidcrystal display is backlit with light-emitting diodes.
 25. A variablereflectance mirror element according to claim 13, further comprising atleast one optical thin film disposed next to the reflective polarizer soas to enhance a reflectivity of the reflective polarizer.
 26. A variablereflectance mirror element according to claim 25, wherein the at leastone optical thin film includes a dichroic thin-film stack.
 27. Avariable reflectance mirror element according to claim 13, wherein thereflective polarizer comprises a switchable cholesteric elementincluding a cholesteric medium, the switchable cholesteric elementdisposed between the electro-optical medium and the electronic device.28. A variable reflectance mirror element according to claim 27, whereinthe cholesteric medium is characterized by a variable pitch.
 29. Avariable reflectance mirror element according to claim 27, wherein themirror element is characterized by a reflectivity that can be set to anyspecified value within a range.
 30. A variable reflectance mirrorelement according to claim 27, wherein the mirror element ischaracterized by at least three discrete states of reflectivity.
 31. Avariable reflectance mirror element according to claim 27, wherein anoverall reflection, by the mirror element, of light incident on thefirst surface is at least sixty percent.
 32. A variable reflectancemirror element according to claim 13, the mirror element configuredwithin a rearview mirror assembly further comprising at least one deviceselected from the group consisting of an interior illumination assembly,an exterior light control, a moisture sensor, an information display, alight sensor, a blind spot indicator, a turning signal indicator, anapproach warning, an operator interface, a compass, a temperatureindicator, a voice actuated device, a microphone, a dimming circuitry, aGPS device, a telecommunication system, a navigation aid, a lanedeparture warning system, an adaptive cruise control, a vision system, arear vision system and a tunnel detection system.
 33. A variablereflectance mirror element according to claim 13, wherein the reflectivepolarizer functions as the second electrode.
 34. A variable reflectanceelement according to claim 13, wherein the mirror element ischaracterized by a transmittance that is a function of voltage appliedbetween the first and second electrodes.
 35. A variable reflectancemirror element for use in a rearview mirror assembly having anelectronic device positioned behind the mirror element for transmittingor receiving light of a first polarization, the mirror elementcomprising: a first substrate having first and second surfaces; a secondsubstrate having third and fourth surfaces, the second and firstsubstrates positioned in a spaced-apart relationship such that thesecond and third surfaces face each other; a first electrode carried ona surface of the first substrate; a second electrode carried on asurface of the second substrate; an electrochromic medium providedbetween the first and second substrates; a reflective polarizer forsubstantially transmitting light of a first polarization andsubstantially reflecting light of a second polarization, the secondpolarization being opposite the first polarization, the reflectingpolarizer positioned on or near the second substrate such that theelectronic device transmits or receives light of the first polarizationthrough the reflective polarizer; and at least one optical filmenhancing a reflectivity of the reflective polarizer.
 36. A variablereflectance mirror element according to claim 35, wherein the mirrorelement is characterized by a reflectance of at least fifty percent. 37.A variable reflectance mirror element according to claim 36, the mirrorelement configured within a rearview mirror assembly further comprisingat least one device selected from the group consisting of an interiorillumination assembly, an exterior light control, a moisture sensor, aninformation display, a light sensor, a blind spot indicator, a turningsignal indicator, an approach warning, an operator interface, a compass,a temperature indicator, a voice actuated device, a microphone, adimming circuitry, a GPS device, a telecommunication system, anavigation aid, a lane departure warning system, an adaptive cruisecontrol, a vision system, a rear vision system and a tunnel detectionsystem.
 38. A variable reflectance mirror element according to claim 35,wherein the mirror element is characterized by a reflectance of at leastsixty percent.
 39. A variable reflectance mirror element according toclaim 35, wherein the reflective polarizer includes multiple layers ofplastic film.
 40. A variable reflectance mirror element according toclaim 35, wherein the reflective polarizer includes a wire-gridpolarizer.
 41. A variable reflectance mirror element according to claim35, wherein the reflective polarizer is laminated to the fourth surface.42. A variable reflectance mirror element according to claim 35, whereinthe reflective polarizer is laminated to the third surface.
 43. Avariable reflectance mirror element according to claim 35, wherein theelectronic device is a liquid crystal display.
 44. A variablereflectance mirror element according to claim 43, wherein the liquidcrystal display is a video display.
 45. A variable reflectance mirrorelement according to claim 43, wherein an area of the liquid crystaldisplay is substantially equal to a viewing area of the variablereflectance mirror element.
 46. A variable reflectance mirror elementaccording to claim 43, wherein the liquid crystal display ischaracterized by a width between 6 and 14 inches and a width-to-heightratio of the liquid crystal display is between 2:1 and 12:1.
 47. Avariable reflectance mirror element according to claim 46, wherein thewidth-to-height ratio of the liquid crystal display is between 3:1 and6:1.
 48. A variable reflectance mirror element according to claim 46,wherein the width-to-height ratio of the liquid crystal display isbetween 4:1 and 5:1.
 49. A variable reflectance mirror element accordingto claim 43, wherein the liquid crystal display is backlit withlight-emitting diodes.
 50. A variable reflectance mirror elementaccording to claim 35, wherein the at least one optical thin filmincludes a dichroic thin-film stack.
 51. A variable reflectance mirrorelement according to claim 35, wherein the reflective polarizerfunctions as the second electrode.
 52. A variable reflectance mirrorelement according to claim 35, wherein the reflective polarizercomprises a switchable cholesteric element including a cholestericmedium, the switchable cholesteric element disposed between theelectro-optical medium and the electronic device.
 53. A variablereflectance mirror element according to claim 52, wherein thecholesteric medium is characterized by a variable pitch.
 54. A variablereflectance mirror element according to claim 52, wherein the mirrorelement is characterized by a reflectivity that can be set to anyspecified value within a range.
 55. A variable reflectance mirrorelement according to claim 52, wherein the mirror element ischaracterized by at least three discrete states of reflectivity.
 56. Avariable reflectance element according to claim 35, wherein the mirrorelement is characterized by a transmittance that is a function ofvoltage applied between the first and second electrodes.